EP3442309B2 - Procédé de fabrication d'un élément textile plat conducteur électrique - Google Patents

Procédé de fabrication d'un élément textile plat conducteur électrique Download PDF

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Publication number
EP3442309B2
EP3442309B2 EP17185132.2A EP17185132A EP3442309B2 EP 3442309 B2 EP3442309 B2 EP 3442309B2 EP 17185132 A EP17185132 A EP 17185132A EP 3442309 B2 EP3442309 B2 EP 3442309B2
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EP
European Patent Office
Prior art keywords
layer
electrically conductive
textile carrier
carrier layer
process according
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Application number
EP17185132.2A
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German (de)
English (en)
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EP3442309B1 (fr
EP3442309A1 (fr
Inventor
Andreas Gerken
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Benecke Kaliko AG
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Benecke Kaliko AG
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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional [2D] plane, e.g. plate-heater
    • H05B3/34—Heating elements having extended surface area substantially in a two-dimensional [2D] plane, e.g. plate-heater flexible, e.g. heating nets or webs
    • H05B3/342—Heating elements having extended surface area substantially in a two-dimensional [2D] plane, e.g. plate-heater flexible, e.g. heating nets or webs heaters used in textiles
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/03—Use of materials for the substrate
    • H05K1/038—Textiles
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/09—Use of materials for the conductive, e.g. metallic pattern
    • H05K1/092—Dispersed materials, e.g. conductive pastes or inks
    • H05K1/095—Dispersed materials, e.g. conductive pastes or inks for polymer thick films, i.e. having a permanent organic polymeric binder
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/013—Heaters using resistive films or coatings
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/017—Manufacturing methods or apparatus for heaters

Definitions

  • the invention relates to a method for producing a flexible textile electrically conductive surface element.
  • Heatable surfaces such as seat heating are now standard equipment in many vehicles.
  • directly heated materials that have an integrated electrical heating function are also used.
  • any material that has an electrical resistance when current flows through it, which leads to the material heating up, can be used as an electrical resistance heater.
  • Stranded heaters are still widely used as seat heaters, i.e. heating wires embedded in textile material, leather or artificial leather. These are prone to breakage, have relatively large unheated areas between the strands and cannot be changed in terms of electrical resistance.
  • electrically conductive textiles can also be used as electrical resistance heating.
  • Such textiles with electrically conductive fibers are used, for example, in EP 1 835 786 A1 , WO 2007/031324 A1 , DE 42 33 118 A1 , EN 41 10 36 425 A1 , EN 10 2005 050 459 B3 or DE 41 24 684 A1
  • the production of such textiles is usually complex and very expensive compared to standard textiles used in automotive artificial leather, which is an obstacle to serial automotive production.
  • EN 10 2012 000 445 A1 discloses a seat heater for a cushion of a vehicle seat with at least one heating element that can be controlled by a control device and supplied with electrical current, wherein the heating element has a heating layer, for example based on carbon nanotubes, which is formed by a heating varnish.
  • a heating layer for example based on carbon nanotubes, which is formed by a heating varnish.
  • the WO 2008/075915 discloses a heatable material for, in particular, military clothing, which consists of a textile base layer to which a conductive layer and, in addition, a heatable layer/heating layer are applied, as well as a surface insulating layer.
  • the conductive layer and the heating layer can be arranged in different ways, but both are always present.
  • an additional smoothing layer is provided (primer layer 200), which is intended to smooth the textile and prevent the conductive layers from penetrating into cavities in the textile.
  • the substrate to be printed should be as smooth as possible, which can be achieved with textiles by coating the substrate over the entire surface.
  • the disadvantage here is that the heating paint can have chemical interactions with such coating systems, so that the electrical conductivity can change over time (see test results).
  • such a coating significantly changes the textile character and a defined, reproducible coating is hardly possible with very light textiles.
  • the applied conductive structures can be protected against mechanical, corrosive or moisture influences. This can be done, for example, by an additional polymer layer, film or textile. The necessary additional process step with the additionally required covering material can be perceived as disadvantageous.
  • the electrically conductive polymer layer can be applied to a separate textile carrier or film, which can then be used separately or in a composite.
  • the composite can be made by laminating or mechanical methods such as sewing, riveting, stapling or reversibly.
  • the invention was therefore based on the object of providing a method for producing a flexible textile electrically conductive surface element which is easy to produce, has good bonding between the electrically conductive layer and the textile carrier layer and the smallest possible change in electrical conductivity with ageing, especially under
  • the problem is solved by printing an electrically conductive structure, for example for applying electrically resistive heating structures, capacitive sensors or antennas, onto a fabric that has previously been smoothed using a calendering process.
  • the printing is advantageously carried out using a rotary screen printing process.
  • the object of the present invention is achieved by a method for producing a flexible textile electrically conductive surface element according to claim 1.
  • At least one main surface of the textile carrier layer is smoothed before the application of the crosslinkable polymer dispersion according to step b) such that after smoothing it has an Sz value of 1.0 mm or less, determined according to DIN EN ISO 25178-2:2012, preferably of 0.5 mm or less, wherein the crosslinkable polymer dispersion is applied directly to the smoothed surface of the textile carrier layer.
  • the invention is based on the finding that by previously smoothing the textile carrier layer and immediately applying a crosslinkable aqueous polymer dispersion containing electrically conductive particles, a layer composite can be produced whose electrical conductivity is hardly subject to aging, especially when aged at elevated temperatures.
  • high conductivities can be achieved with comparatively small amounts of aqueous polymer dispersion containing electrically conductive particles, since a smaller proportion of the dispersion sinks into the textile carrier layer due to the previous smoothing.
  • Crosslinkable aqueous polymer dispersions containing electrically conductive particles can be used, for example, as described in EP 2 457 944 B1 are described. In principle, however, other dispersions known to the person skilled in the art can also be used within the scope of the present invention.
  • the polymer dispersion containing electrically conductive particles can be applied in any pattern, such as line, cross or diamond patterns, or even over the entire surface.
  • the textile carrier layer After smoothing, the textile carrier layer then has an Sz value of 1.0 mm or less, determined according to DIN EN ISO 25178-2:2012, preferably 0.5 mm or less. This is particularly advantageous because it means that a smaller application amount of the polymer dispersion containing electrically conductive particles is sufficient to achieve the desired conductivity.
  • By smoothing before applying the crosslinkable aqueous polymer dispersion it can sink less into the gaps in the carrier layer. In this way, it is therefore possible to produce, for example, an artificial leather layer structure with an electrically conductive layer, for example for a car seat with integrated seat heating.
  • This layer structure is unusual in that smoothed, for example calendered, textile carrier layers are not usually used for artificial leather layer structures.
  • the smoothing step is preferably carried out in such a way that the Sz value of the textile carrier layer, which is a measure of the roughness of the fabric, is reduced during smoothing to 80% of the Sz value before smoothing, determined according to DIN EN ISO 25178-2:2012, preferably to 60% or less of the Sz value before smoothing.
  • the smoothing of at least one main surface of the textile carrier layer is carried out in a calender under heating, the thickness of the textile carrier layer preferably being reduced by at least 40%.
  • Typical temperatures for smoothing in a calender are in the range from 180 to 230 °C, preferably from 190 to 200 °C. The abovementioned temperatures apply in particular to the carrier layers made of polyester which are preferred according to the invention, in particular in the form of polyester fabrics.
  • the smoothing of at least one main surface of the textile carrier layer is carried out by applying a thermoplastic polymer while heating, in particular by means of a calender.
  • the thermoplastic polymer can be selected from polyesters, polyamides, polyolefins, polyurethanes, PVC, polyacrylonitrile, polyvinyl alcohol or copolymers or mixtures of these.
  • the textile carrier layer used in the process according to the invention can comprise or consist of, for example, a scrim, knitted fabric, woven fabric or nonwoven fabric, wherein the textile carrier layer in particular comprises or consists of a woven fabric.
  • the textile carrier layer can be made of a material selected from the group comprising polyester, polyamides, polyolefins, polyurethanes, PVC, aramids, polyacrylonitrile, Polyvinyl alcohol, poly(p-phenylene-2,6-benzobisoxazole) or copolymers or mixtures of these.
  • the textile carrier layer can have a basis weight of 250 g/m 2 or less, in particular from 20 to 150 g/m 2 , preferably 40 to 100 g/m 2 .
  • the conductive structures of the fabric printed in this way can be contacted particularly well.
  • the crosslinkable aqueous polymer dispersion containing electrically conductive particles can in principle be applied in any suitable manner known to the person skilled in the art, for example by spraying, dipping, brush application or by printing processes.
  • the crosslinkable aqueous polymer dispersion containing electrically conductive particles is very preferably applied using a screen printing process, in particular a rotary screen printing process. This process is advantageous because it enables a very uniform and very reproducible application over the duration of the process, so that the coated fabrics show as little fluctuation in electrical conductivity as possible.
  • the application quantity can be kept low with screen printing and rotary screen printing processes, which makes the process more economical.
  • Coated or uncoated metal particles, coated glass, ceramic, plastic particles or mixtures of these can be used as electrically conductive particles, to name just a few.
  • Silver-coated copper particles are particularly suitable because they are characterized by good electrical conductivity, good corrosion resistance and an acceptable price.
  • the surface element produced by the process according to the invention is preferably characterized by a lateral specific conductivity of at least 0.5 S/cm, preferably at least 2.0 S/cm.
  • the conductivity can be determined in a manner known per se via a resistance/conductivity measurement using conventional measuring devices.
  • the invention can provide for one or more electrical contacts to be attached to the electrically conductive layer. Contacting of such composite materials according to the invention can be achieved by crimping or clinching electrically conductive conductors or in such a way that no adhesive is applied locally at defined points between the printed fabric and the composite material during lamination, so that these points are accessible for later contacting.
  • thermoplastic adhesive material when laminating the printed fabric so that the bond can be locally released by heating at the point to be contacted, making this point accessible for contacting.
  • the surface element can be partially or completely coated on one or both main surfaces with at least one further layer, in particular with a cover layer. This can be done, for example, via a laminating step in a manner known per se, for example using pressure- or thermally activated adhesives, thermoplastic adhesive webs, reactive single- or multi-component, preferably low-solvent or solvent-free adhesive masses, gelling polymer masses or elastomer-based adhesives.
  • the plastic layer can therefore be produced by laminating with a thermoplastic adhesive, ideally with thermoplastic adhesive web or with a thermoplastic powder. If air and water vapor permeability is to be maintained, a textile or open-pore foam must be used.
  • the layer or layers can serve as mechanical protection or protection against moisture or corrosion and the like, or they can also serve to aesthetically design the surface element.
  • the cover layer can be a decorative layer and in particular can be a compact or foamed plastic layer that has an embossing on its upper side, in particular a grain embossing.
  • a flat "functional mat” can also be created
  • the calendered fabric is laminated with a soft polyurethane foam or fleece after printing with the electrically conductive structure, preferably using a flame, adhesive or web lamination.
  • the conductive structures can be on the outside after connection using the aforementioned lamination methods, whereby this is then preferably protected by an additional lamination.
  • a soft polyurethane foam is preferably applied here using a flame, web lamination or lamination with another thermoplastic adhesive system.
  • other textiles, fleeces or films can also be laminated as a protective layer. Lamination using water-based or solvent-based adhesives is also possible here but not preferred due to the negative interactions and the deterioration of the electrical conductivity after heat stress.
  • the additional layer is not applied as a water- or solvent-based layer, but as a compact layer, for example from a melt or in the form of a film, which is connected to the layer structure by melting or gluing.
  • a water- or solvent-based layer to the conductive layer leads to a layer composite in which the electrical conductivity is subject to considerable aging, so that after just one week of warm storage at 90°C, considerable losses in electrical conductivity can be observed.
  • Electrically conductive textiles produced in this way can be laminated on the functionalized side with an additional textile, film or foam by laminating them with a thermoplastic adhesive such as an adhesive web. Flame lamination with a polyurethane foam is also possible. Such composite materials can then be used flexibly behind any surface (e.g. behind leather, artificial leather, textiles or other surface materials).
  • the functionalized textiles can also be laminated as a carrier textile to form a single or multi-layer composite.
  • the composite according to the invention is completed but can still be further laminated, e.g. with additional films or foams.
  • the lamination is carried out in such a way that the functionalized layer is on the outside using any laminating adhesive, this can be laminated with another textile, film or foam using a thermoplastic adhesive and is then protected.
  • the underlying composite can also be an existing composite structure that already contains at least one textile layer.
  • thermoplastic adhesives can be designed as films, powders, microgranules, previously melted thermoplastic adhesives (which are then printed on with an engraved roller, for example) and preferably as thermoplastic adhesive webs. All of these thermoplastic adhesives can also be reactive, such as moisture-curing reactive polyurethane hotmelt adhesive systems,
  • the crosslinkable aqueous polymer dispersion containing electrically conductive particles is applied to the smoothed surface of the textile carrier layer according to step b) and optionally the at least one further layer is applied in a roll-to-roll process.
  • This is advantageous because this production method allows for quick and cost-effective production.
  • it is also possible to produce the surface element in a parts production process, e.g. with screen printing tables or plate presses.
  • Another disclosed but not inventive subject matter relates to a flexible textile electrically conductive surface element produced by a method in accordance with the invention.
  • the invention thus enables the production of electrically functionalized textile fabrics (e.g. for the integrated production of resistive heaters, antennas, capacitive switches and controllers, seat occupancy detection, sensors, etc.) that can be used flexibly behind any surface material.
  • the textile base makes the fabrics resistant to stretching during production using the roll-to-roll process or during processing and use, but at the same time flexible, especially when thin textiles are used.
  • these composite structures have good permeability to air and water vapor, which is important when lamination with other materials or in applications in the seating area for improved climate comfort.
  • plastic-coated decorative materials artificial leather
  • a polyester lining 130 g/m 2 , thickness approx. 500 ⁇ m
  • a PES fabric 47 g/m 2
  • the calendering reduced the original thickness of the fabric from approx. 200 to approx. 100 ⁇ m.
  • PES lining is also used as a lining material for suits, but in terms of smoothness, this textile is surpassed by the calendered PES fabric. Smoothness is determined according to DIN EN ISO 25178-2:2012.
  • the electrically conductive paste was a recipe based on a recipe with 44 wt.% of the 50 wt.% aqueous polyurethane-polyester dispersion (Impranil DLP), 55 wt.% electrically conductive particles and 1 wt.% isocyanate crosslinker.
  • the current intensity is determined at an applied voltage of 8 V: sample Conditioning Voltage [V] Current [A] Power at 8V [W] 1 a without 8th 2.9 23.2 1 b 7 days, 90 °C 8th 2.9 23.2 2 a without 8th 2.9 23.2 2 B 7 days, 90 °C 8th 0.7 5.6 3 a without 8th 1.8 14.4 3 b 7 days, 90 °C 8th 1.2 9.6 4 a without 8th 2.8 22.4 4 b 7 days, 90 °C 8th 2.8 22.4 5 a without 8th 3.9 31.2 5 b 7 days, 90 °C 8th 2.6 20.8 6 a without 8th 4.3 34.4 6 b 7 days, 90 °C 8th 4.3 34.4
  • Samples 1 a/1 b show that the smooth surface of the polyester lining after printing with the conductive paste results in good conductivity with good thermal performance, which does not change even after aging (7 days at 90°C). However, if one tries to protect this electrically conductive coating from mechanical and/or other environmental influences by coating it with an aqueous polyurethane dispersion, one initially obtains unchanged good conductivity, but this deteriorates significantly after thermal aging (7 days at 90°C) (samples 2a/2b).
  • advantageous composite structures can be produced by using textiles with a smooth surface, such as fabrics based on polyesters, polyamides, polyolefins or cotton/polyester, or knitted fabrics such as interlock, single jersey or knitted fabrics with inserted lining threads on the same material basis, especially if these textile fabrics have been calendered or embossed with heated rollers or plates to smooth them.
  • textile fabrics can then ideally be printed with electrically conductive mass using a screen printing process, which can be carried out as a roll-to-roll process or with screen printing tables.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Laminated Bodies (AREA)

Claims (11)

  1. Procédé de production d'un élément de surface textile flexible électriquement conducteur, le procédé comprenant les étapes suivantes :
    a) fournir une couche de support textile ;
    b) appliquer une dispersion aqueuse de polymère réticulable contenant des particules électriquement conductrices sur la surface de la couche de support textile et
    c) faire durcir la dispersion de polymère pour produire une couche électriquement conductrice,
    caractérisé en ce qu'au moins une surface principale de la couche de support textile est lissée avant l'application de la dispersion de polymère réticulable de façon à avoir, après le lissage, une valeur Sz de 1,0 mm ou moins, déterminée selon la norme DIN EN ISO 25178-2:2012, de préférence de 0,5 mm ou moins, la dispersion de polymère réticulable étant appliquée directement sur la surface lissée de la couche de support textile,
    le lissage de l'au moins une surface principale de la couche de support textile étant effectué avec chauffage dans une calandre, l'épaisseur de la couche de support textile étant de préférence réduite d'au moins 40 %.
  2. Procédé selon la revendication 1, caractérisé en ce que la valeur Sz de la couche de support textile lors du lissage est réduite à 80 % de la valeur Sz avant lissage, déterminée selon la norme DIN EN ISO 25178-2:2012, de préférence à 60 % ou moins de la valeur Sz avant le lissage.
  3. Procédé selon l'une des revendications précédentes, caractérisé en ce que la couche de support textile comprend un canevas, un tricot, un tissé ou un non-tissé, ou est constituée de celui-ci, en particulier la couche de support textile comprenant un tissu ou étant constituée de celui-ci .
  4. Procédé selon l'une des revendications précédentes, caractérisé en ce que la couche de support textile a un poids par unité de surface de 250 g/m2 ou moins, en particulier de 20 à 150 g/m2, de préférence de 40 à 100 g/m2.
  5. Procédé selon l'une des revendications précédentes, caractérisé en ce que l'application de la dispersion aqueuse de polymère réticulable contenant des particules électriquement conductrices est effectuée par un procédé de sérigraphie.
  6. Procédé selon l'une des revendications précédentes, caractérisé en ce que la dispersion aqueuse de polymère réticulable contient un prépolymère polyuréthanne.
  7. Procédé selon l'une des revendications précédentes, caractérisé en ce que l'élément de surface présente une conductivité spécifique latérale d'au moins 0,5 S/cm, de préférence d'au moins 2,0 S/cm.
  8. Procédé selon l'une des revendications précédentes, caractérisé en ce qu'un ou plusieurs contacts électriques sont fixés sur la couche électriquement conductrice.
  9. Procédé selon l'une des revendications précédentes, caractérisé en ce que l'élément de surface est partiellement ou totalement revêtu, sur une surface principale ou les deux, d'au moins une autre couche, notamment d'une couche de recouvrement, la couche de recouvrement étant de préférence une couche décorative qui se présente notamment sous la forme d'une couche matière synthétique compacte ou expansée et qui est pourvue sur sa face supérieure d'un gaufrage, en particulier d'un gaufrage grené.
  10. Procédé selon la revendication 9, caractérisé en ce que l'autre couche n'est pas appliquée comme couche à base d'eau ou de solvant.
  11. Procédé selon l'une des revendications précédentes, caractérisé en ce que l'application de la dispersion aqueuse de polymère réticulable contenant des particules électriquement conductrices sur la surface lissée de la couche de support textile selon l'étape b) et éventuellement l'application de l'au moins une autre couche sont effectuées selon un processus rouleau à rouleau (roll-to-roll processing) .
EP17185132.2A 2017-08-07 2017-08-07 Procédé de fabrication d'un élément textile plat conducteur électrique Active EP3442309B2 (fr)

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Application Number Priority Date Filing Date Title
EP17185132.2A EP3442309B2 (fr) 2017-08-07 2017-08-07 Procédé de fabrication d'un élément textile plat conducteur électrique

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Application Number Priority Date Filing Date Title
EP17185132.2A EP3442309B2 (fr) 2017-08-07 2017-08-07 Procédé de fabrication d'un élément textile plat conducteur électrique

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EP3442309A1 EP3442309A1 (fr) 2019-02-13
EP3442309B1 EP3442309B1 (fr) 2021-06-30
EP3442309B2 true EP3442309B2 (fr) 2024-05-15

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FR3120077B1 (fr) 2021-02-19 2023-03-03 Porcher Ind Composant en textile avec électronique imprimée
CN113818255B (zh) * 2021-09-09 2023-08-22 东风汽车集团股份有限公司 一种基布和合成革及其制备方法和应用
DE202024105566U1 (de) 2024-05-23 2024-12-09 imbut GmbH Formflexibles elektrisches Flächenheizelement

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JPH03237799A (ja) † 1990-02-14 1991-10-23 Unitika Ltd 導電性織物およびその製造方法
WO2008060101A1 (fr) † 2006-11-14 2008-05-22 Kolon Glotech, Inc. Tissu conducteur imprimé souple, et son procédé de fabrication
WO2008075915A1 (fr) † 2006-12-20 2008-06-26 Kolon Glotech, Inc. Tissu chauffant et procédé de fabrication associé
EP2457944B1 (fr) † 2010-11-30 2013-07-03 Benecke-Kaliko AG Mélange de polymères
WO2016173726A1 (fr) † 2015-04-28 2016-11-03 Benecke-Kaliko Ag Composition de matières électroconductrices

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